Easy tear boxes

ABSTRACT

A cardboard container includes a removable top tear panel that when removed enables picking of items from the container and a removable front tear panel that when removed enables picking of items from the container. Either or both the top tear panel and the front tear panel may be removed. The front panel includes an un-removable, U-shaped lip for inhibiting items from accidental removal from the container.

BACKGROUND

Containers, such as cardboard boxes, are used in vast quantities for delivering and storing items. For example, a cardboard box is often used to hold and transport several products for shipping to a retailer, which products themselves are housed in a box. The inner boxes holding the products sometimes are laminated, branded boxes that are intended for displaying the product on a shelf in a retail setting. For example, the branded boxes of some candy products include a perforated front panel and top panel that can be removed from its base and sidewalls such that an end purchaser can grasp the product and remove it from the box. Typically, the removable front panel and top panel together form a unitary combination. Alternatively, in some configurations only the top portion of the retail box is removable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a container illustrating aspects of the present invention;

FIG. 2 is rear perspective view of the container of FIG. 1;

FIG. 3 is top view of a die cut sheet used for forming the container of FIG. 1;

FIG. 4 is a perspective view of the container of FIG. 1 illustrating the opening process for a front tear panel; and

FIG. 5 is a perspective view of the container of FIG. 4 illustrating the opening process for a top tear panel.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

A container disclosed herein is versatile, as it has a configuration in which it is a cuboid carton and additional configurations to enable it to stow items for picking. In this regard, container has a configuration in which its top wall is removed, another configuration in which its front wall is removed, and yet another configuration in which both its top wall and its front wall are removed. The removability of the top wall and/or front wall enables the items within the box to be stowed and picked by a human or robotic arm. The front wall includes a lip that restrains or inhibits items from falling out or being inadvertently knocked out of the open front wall.

Thus, the container may include: a removable top tear panel that when removed enables picking of items from the container and a removable front tear panel that when removed enables picking of items from the container. The front panel includes an un-removable, U-shaped lip for inhibiting items from accidental removal from the container. Thus, in a shipping configuration the container is an enclosed carton and in a picking configuration (i) containers may be stacked such that a top container in the stack has the top tear panel and front tear panel removed and such that lower containers in the stack have only the front tear panel removed, or (ii) containers may be placed on a shelf where either or both of the front tear panel and rear tear panel is removed.

According to another aspect, the container includes: a base wall, a top wall opposite the base wall, a front wall, and a rear wall opposite the front wall, an upstanding left sidewall, and an opposing upstanding right sidewall. The sidewalls (i) span vertically between edges of the base wall and the top wall and (ii) span horizontally between edges of the front wall and the rear wall. The front wall includes a front tear panel and a lip below the tear panel. The front tear panel is bounded by side perforations, lower perforations that join the front tear panel to the lip, and upper perforations. The top wall including a top tear panel bounded by side perforations, rear perforations, and front perforations. The container is configured such that (i) the top tear panel is removable by tearing the top panel perforations independent of the front tear panel, (ii) the front tear panel is removable by tearing the front panel perforations independent of the top tear panel and the lip, (ii) the top tear panel and front tear panel are removable together by tearing at least some of the top panel perforations and front panel perforations. Thus, removal of the top panel and/or side panel enables picking items from the container.

FIGS. 1 and 2 illustrate a preferred embodiment of a container 10. FIG. 3 illustrates the die cut sheet 10′ of cardboard for forming container 10. Preferably, container 10 is formed on a conventional cardboard, such as EB flute, such that container 10 is suitable for transporting products up to 5 kg, and in some circumstances up to 10 kg.

Container 10 includes a bottom wall 12, a top wall 14, a front wall 20, a rear wall 50, and left and right sidewalls 80L and 80R. The orientations top, bottom, left, and right are referred to according to viewing front wall 20 while container 10 is in its as-used state, with bottom wall 12 resting on a surface.

As best shown in FIG. 3, top wall 14 in the embodiment shown in the figures is formed by a top front flap 22, a top rear flap 52, and top left and top right flaps 82 L and 82R. Top front flap 22 is joined to front sidewall 20 at a top front crease 24. Top rear flap 52 is joined to rear wall 50 at top rear crease 54. Top left and right flaps 82L and 82R are joined to sidewalls 80L and 80R by top left and top right creases 84L and 84R. Thus, flaps 22 and 52 are folded at creases 24 and 54 such that distal edges of flaps 22 and 52 are closely spaced apart by a few millimeters such that flaps 22 and 52 form a layer of top wall 14. And flaps 82L and 84R are folded at creases 84L and 84R such that the distal edges of flaps 82L and 84R are spaced apart by a few millimeters and such that flaps 82L and 82R form another layer of top wall 14.

Bottom wall 12 in the embodiment shown in the figures is formed by a bottom front flap 46, a bottom rear flap 76, and bottom left and bottom right flaps 86L and 86R. Bottom front flap 46 is joined to front sidewall 20 at a bottom front crease 48. Bottom rear flap 76 is joined to rear wall 50 at bottom rear crease 78. Bottom left and right flaps 86L and 86R are joined to sidewalls 80L and 80R by bottom left and bottom right creases 88L and 88R. Thus, flaps 46 and 76 are folded at creases 48 and 78 such that distal edges of flaps 46 and 76 are closely spaced apart by a few millimeters and such that flaps 46 and 76 form a layer of bottom wall 12. And flaps 86L and 86R are folded at creases 88L and 88R such that the distal edges of flaps 86L and 86R are spaced apart by a few millimeters and such that flaps 86L and 86R form another layer of bottom wall 14. All flaps are separated by cuts 92.

Preferably, front wall 20, rear wall 50, and sidewalls 80L and 80R are single sheets of cardboard. The present invention is not limited to the particular configuration of the sheets described herein, as a person familiar with carton technology will understand that several configurations are understood in the field.

Four vertical creases 90 connect front wall 20, sidewalls 80L and 80R, and rear wall 50 together. In this regard, a glue tab 94 extends from one of the walls (the rear wall 50 as oriented in the figures) to provide a gluing surface to join the box together. The present invention is not limited to the particular means for joining the box, and the present invention encompasses any types of adhesive, tape, or other means.

Several perforations and cutouts provide functionality to container 10. A top front perforation 25 is located coextensive with or near top front crease 24. Preferably top front perforation 25 is discontinuous, as explained more fully below. A top rear perforation 55 is located coextensive with or near top rear crease 54. Top rear perforation is interrupted near its center by a rear tab 68, as explained more fully below. And top side perforations 85L and 85R are located coextensive with or near top left and top right creases 84L and 84R. Perforations 25, 55, and 85L and 85R preferably are in or near the corresponding creases to maximize the open area when the top tear panel is removed. The term “perforation” is broadly used herein to refer to intermittent partial or though-cuts or scoring or like features to facilitate tearing along the line.

Front wall 20 includes a lip 28 and a tear panel 30. Lip 28 is a U-shaped, un-removable portion of front wall 20 (that is, there are no perforations that facilitate lip 28 to be removed from the container.). Lip 28 includes a horizontal portion 32 that extends laterally between creases 90 that merge into sidewalls 80L and 80R and a pair of opposing lift and right sides or legs 34L and 34R. Legs 34L and 34R terminate at upper lips or ends 36L and 36R, and the outboard sides of legs 34L and 34R terminate at vertical creases 90 that merge into sidewalls 80L and 80R.

Tear panel 30 is separated from lower portion 32 of lip 28 by a bottom tear panel perforation 40 a, is separated from legs 34L and 34R by a pair of opposing perforations 40 b, and is separated from tear panel upper lips 36L and 36R by upper lip perforations 40 c. A pair of opposing perforations 40 e extend from the outboard ends of top front perforation 25 to the outboard ends of lip perforations 40 c. The upper boundary of tear panel 30 is formed by top front perforation 25 and a tab perforation 96. An upper tab 38 is formed by tab perforation 96 and is by a portion of top front crease 24. A lower perforation 40 d, which may also be a cutout, forms a finger access 42.

Rear tab 68 preferably is formed by a rear tab perforation 70, and tab 68 is joined to top rear flap 82 by top rear crease 55 such that tab 68 is free from rear wall 50 upon rupturing of perforation 70.

Top panel 60 is formed by top rear perforation 55, top side perforations 85L and 85R, top front perforation 25 and rear tab perforation 70. In this regard, when desired to remove to panel 60, a user may insert his finger into a finger hole 98 which aides in pulling upwardly on rear tab 68 to rupture rear tab perforation 70, as illustrated in FIG. 5. Additional upward pulling propagates the rupture through top rear perforation 55. A user may continue to rupture top side perforations 85L and 85R and top front perforation 25 until the top of container 10 is open and the items within container 10 are accessible from above.

When desired to remove front panel 30, a user may insert a finger into aperture 42 and pull upwardly on tear panel 30 to rupture perforations 40 a, 40 b, 40 c, 40 e, 25, and 96 to free front tear panel 30 from the remainder of container 10, as best shown in FIG. 4.

In circumstances in which containers 10 are stacked, it is preferable that only the front tear panels 30 of the containers in the stack are removed to provide vertical stacking strength to the containers, if needed. The top container 10 in the stack, of course, may have either or both its tear panels 30 and 60 removed, as there is no top load on the uppermost container 10. In circumstances in which a container is placed on a shelf, it is preferably that front tear panel 30 is removed and top tear panel 60 may optionally be removed if desired by the particular application.

During the process of removing items from container 10. Lip 28 inhibits articles from inadvertently falling or being knocked out of container 10. In this regard, leg width D1, bottom lip height D2, and dimension D3 (which is the distance that lip ends 36L and 36R are spaced apart from top flap 22, and therefore determines the height of legs 34L and 34R) may be chosen depending on the other box dimensions and based on the sizes of items desired to be inducted into the and picked out of the box. Dimensions D4 and D5 of finger aperture 42 and dimensions of finger aperture 98 (not called out in the figures) and rear tab dimensions D6 and D7, which preferably are similar to front tab dimensions (not called out in the figures for clarity) may be chosen according to conventional ergonomic principles, as will be understood by persons familiar with carton technology. The dimensions of lip 38 and lip surface 32 may be chosen such that taping for holding the box together has a surface on which to grip.

Container 10 is suited for shipping items, and then stowing the items after receipt of container 10 while container 10 is its open configuration—that is, while either or both of tear panels 30 and 60 are removed—to enable picking of items from container 10 by either a human or a robot. Container 10 thus preferably is not laminated or branded but conventional single ply or double ply corrugated paperboard or cardboard with a one dimensional or two dimensional code or other identifying, machine-readable indicia. The term “cardboard” is used herein broadly to refer to any type of corrugated paperboard, fiberboard, and like carton material.

The dimensions of carton 10 are reflected in FIG. 3 as overall length L1 and height H2. Length L1 is the sum of wall widths L2, L3, L4, and L5. As box is rectangular, lengths L2 and L4 of the front and rear walls should be the same, and lengths L3 and L5 of the sidewalls should be the same, except for minor variations to accommodate folding if needed. Upper and lower flap heights H3 and H4 should sum to approximately the smallest of L2, L3, L4, and L5 (allowing for a few millimeters clearance when folded) such that when flaps 22, 52, 82L and 82R are folded, they can be glued, taped, or otherwise joined effectively. The specific dimensions of the dimensions, lengths, and widths can be determined according to the desired characteristics of the box and the items contained. For merely one example, L1 may be 1693 mm, L2 and L4 may be 393 mm, L3 may be 442 mm, L5 may be 439 mm, H1 may be 699 mm, H2 may be 307 mm, H3 and H4 may be 196 mm, D1 may be 45 mm, D2 may be 50 mm, D3 may be 234 mm (making leg height 73 mm), D4 may be 25 mm, D5 may be 50 mm, D6 may be 55 mm, and D7 may be 60 mm.

The present invention has been described using one particular example of a container. The present invention is not intended to be limited to any structure described above, such as but not limited to the shapes or sizes of the tear panels, the configuration and orientation of the flaps and walls, specific materials, the shapes and sizes of the overall box, and the like, unless specifically set out in the claims. 

What is claimed:
 1. A container for shipping and then stowing and picking items, the container having a cuboid structure and comprising: a removable top tear panel that when removed enables picking of items from the container; a removable front tear panel that when removed enables picking of items from the container, the front panel including an un-removable, U-shaped lip for inhibiting items from accidental removal from the container; wherein in a shipping configuration the container is an enclosed carton and in a picking configuration (i) containers may be stacked such that a top container in the stack has the top tear panel and front tear panel removed and such that lower containers in the stack have only the front tear panel removed, or (ii) containers may be placed on a shelf where either or both of the front tear panel and rear tear panel is removed.
 2. A container for shipping and then stowing and picking items, the container having a cuboid structure and comprising: a base wall, a top wall opposite the base wall, a front wall, and a rear wall opposite the front wall, an upstanding left sidewall, and an opposing upstanding right sidewall, the sidewalls (i) spanning vertically between edges of the base wall and the top wall and (ii) spanning horizontally between edges of the front wall and the rear wall; the front wall including a front tear panel and a lip below the tear panel; the front tear panel bounded by side perforations, lower perforations that join the front tear panel to the lip, and upper perforations; the top wall including a top tear panel bounded by side perforations, rear perforations, and front perforations; the container being configured such that (i) the top tear panel is removable by tearing the top panel perforations independent of the front tear panel, (ii) the front tear panel is removable by tearing the front panel perforations independent of the top tear panel and the lip, (ii) the top tear panel and front tear panel are removable together by tearing at least some of the top panel perforations and front panel perforations, wherein removal of the top tear panel and/or front tear panel enables picking items from the container.
 3. The container of claim 2 wherein the lip is U-shaped and includes (i) a lower edge that merges into the bottom wall and (ii) opposing side edges that merge into corresponding sidewalls.
 4. The container of claim 3 wherein the top tear panel includes layers, each one of the layers is attached one to one of the rear wall, left sidewall, right sidewall, and front sidewall at a crease and perforations.
 5. The container of claim 3 wherein the top wall layers include a left top flap joined to the left sidewall by a crease and top left flap perforation, and a top right flap joined to the right sidewall by a crease and a right flap perforation, a top rear flap joined to the rear wall by a crease and a top rear perforation, and a top front flap joined to the front wall by a crease and a top front perforation, whereby the top panel is removable by rupturing the top left perforation, the top right perforation, the top rear perforation, and the top front perforation.
 6. The container of claim 5 wherein the bottom wall is formed by a left bottom flap, a right bottom flap, a front bottom flap, and a rear bottom flap; the left bottom flap is attached to the left sidewall at an unperforated crease, the right bottom flap is attached to the right sidewall at an unperforated crease, the front bottom flap is attached to the front wall at an unperforated crease, and a rear bottom flap is attached to the rear wall at an unperforated crease.
 7. The container of claim 6 wherein the container is formed from an unbranded, un-laminated cardboard.
 8. The container of claim 7 wherein the container includes a scan-able label.
 9. A method for containing and enabling picking of items in a container comprising the steps of: in a cuboid, cardboard container that a pair of sidewalls, a bottom wall, a removable top tear panel, a rear wall, and a front wall that includes a removable front tear panel and an un-removable, U-shaped lip; grasping a bottom of the front tear panel and pulling the bottom of the front tear panel outwardly to rupture perforations defining the front tear panel, thereby separating the front tear panel from the top wall, sidewalls, and lip to form a front opening; and picking items from the container through the front opening.
 10. The method of claim 9 further comprising the step of grasping a front of the top tear panel and lifting the top tear panel upwardly to rupture perforations defining the top tear panel, thereby separating the top tear panel from the sidewalls and the rear wall to create a top opening that is continuous with the front opening.
 11. The method of claim 9 further comprising the step of stacking another one of the containers on top of a first one of the containers.
 12. The method of claim 9 wherein the lip is U-shaped and includes (i) a lower wall that merges into the bottom wall and (ii) opposing side legs that merge into corresponding sidewalls.
 13. The method of claim 12 wherein the step of grasping a bottom of the front tear panel includes engaging a finger aperture defined between the front tear panel and the lip lower wall.
 14. The method of claim 10 wherein the top wall includes layers, each one of the layers is attached one to one of the rear wall, left sidewall, right sidewall, and front sidewall at a crease and perforations and the step of lifting the top tear panel includes rupturing the crease and the perforations at the rear wall, left sidewall, right sidewall, and front sidewall.
 15. The method of claim 14 wherein the top wall layers include a left top flap joined to the left sidewall by a crease and top left flap perforation, and a top right flap joined to the right sidewall by a crease and a right flap perforation, a top rear flap joined to the rear wall by a crease and a top rear perforation, and a top front flap joined to the front wall by a crease and a top front perforation, and the step of lifting the top tear panel includes rupturing the top left perforation, the top right perforation, the top rear perforation, and the top front perforation.
 16. The method of claim 15 wherein the step of grasping a front of the top tear panel includes engaging a finger aperture in the rear panel and separating the layers of the top wall at the top left perforation, the top right perforation, the top rear perforation, and the top front perforation.
 17. The method of claim 9 further comprising the step of scanning a label on the container. 